Lonestars DOHC Swap

as most of you know i got a Kia head for really cheap but it has some oil starvation issues in its past life which lead to the cam being rubbed away really badly. also has a bad lifter and roller rocker. im going in there and rebuilding this badboy for some power. i got a few pics, and a partslist. dont know where this will take me yet, but maybe a Hyundai manual will be in the car as well. my plan is for this project to be complete somewhere around the end of the year. here are the pics

http://farm4.static.flickr.com/3635/...6845370162.jpg
http://farm4.static.flickr.com/3585/...843305b7_b.jpg
http://farm4.static.flickr.com/3568/...16ec43bf_b.jpg
http://farm4.static.flickr.com/3430/...bc175cae_b.jpg


Partslist so far
EVO VIII Fuel Rail
EVO VIII Dipstick & Tube
Kia Optima Head w/ Valve Cover
Fidanza Adjustable Cam Gears
Brian Crower 272/272 Cams
EVO VIII Lifters
EVO VIII rockers
Topline Valve Stem Seals
Brian Crower Valve Springs & Retainers
if i decide to port & polish i may get some larger valves but i have yet to decide

more pics

nasty dead lifter
http://farm4.static.flickr.com/3577/...548a7bc9_b.jpg
http://farm4.static.flickr.com/3388/...e7739b01_b.jpg
http://farm4.static.flickr.com/3309/...4829030e_b.jpg
http://farm4.static.flickr.com/3577/...64fed162_b.jpg
http://farm4.static.flickr.com/3173/...c24147cf_b.jpg
journals/cam caps will have to be refinished

well well well lookie what we have here!

finally some engine modding.

Before you do anything with that head, take it all apart and have a machine shop magnaflux it, check for warping and overall spec it out. It will probably cost you $75. That damage on the cam looks really really bad, lack of oil bad enough to cause that could have ruined the head.

yeah the machine shop is taking everything out the head, cleaningi it up, fixing the journals, and installing all the parts for me so theres no room for me to screw things up. my VRG bumper may be for sale soon if anyone wants to trade for an old style VR4

Quote:

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Originally Posted by lonestar22

yeah the machine shop is taking everything out the head, cleaningi it up, fixing the journals, and installing all the parts for me so theres no room for me to screw things up. my VRG bumper may be for sale soon if anyone wants to trade for an old style VR4

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Nice. Its a step ofter overlooked. My machinist had a 2g eclipse head someone brought him to assemblem and deck it, the thing had like $1200 worth of porting and polishing, he spec's it out and its too warped to be used, unrepairable. So the guy spent all that money on porting/polishing for nothing.

what can i run to get rid of the factory rev limiter? im going to be running a maf translator gen2 but i want to be able to rev to the evo redline once this setup is done. any insight?

your 5 speed already? im pretty sure just set it up to run a 3g 5speed ECU and re-flash it to ditch the limiter.

no 5spd yet, thats coming too but i want to have the head done first

Yeah the issue is trying to hack the Auto ECU to change the shift points, it doesnt matter what the redline is if the ECU is telling the trans to shift at a certain RPM, you would never be able to get to redline.

nice man if you got any other questions post them up... my suggestion on valve would be to get supertech nitrate coated valves i have the +1mm i/e in my sonata head

so yesterday i bought...
Brian Crower Stage 2 Camshafts
OEM Mitsu Valve Locks/keepers (why not?)
Topline Intake/Exhaust Valve Guides
Topline Valve Seals...

next on the list is valve springs roller rockers and lifters... and maybe valves. if i get +1mm valves does it have to be on a port and polished head? or is here some way i dont know about to make them fit

picccccs

Quote:

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Originally Posted by lonestar22

so yesterday i bought...
Brian Crower Stage 2 Camshafts
OEM Mitsu Valve Locks/keepers (why not?)
Topline Intake/Exhaust Valve Guides
Topline Valve Seals...

next on the list is valve springs roller rockers and lifters... and maybe valves. if i get +1mm valves does it have to be on a port and polished head? or is here some way i dont know about to make them fit

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I wouldnt order valves or guides until the machinist inspects the head. I know a few guys who bought +1mm oversized valves, had the head spec'd and found out that they could only run .5mm oversize valves due to the edge of the valve being so close to the sealing area around the cylinder. This is typically only an issue on heads that need to be milled down a fair amount to achieve the proper surface finish and flatness.

i got an amazing deal on the parts, but no pics since most are on backorder.

i wouldn't trust anything back ordered rite now the way companies are disappearing these days

ill kill if my money disappears

Quote:

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Originally Posted by lonestar22

ill kill if my money disappears

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as long as you didnt buy them from 3058g you should be OK.

what is this piece back here?
mine comes out sideways and spins around if you try to unscrew it. what does it do?
http://farm4.static.flickr.com/3609/...8b06953e_o.jpg

so this thread is also turning into my manual swap thread now. i went and put a deposit in on a Hyundai Sonata transmission due to the price difference and how close it is to my house. So far no one has tried it yet and there is only little proof that it will fit but we are soon to find out. I still need pretty much ALL the other parts of the transmission.

heres the list of parts i THINK i need. there might be more if so let me know.

Hyundai Sonata transmission
Clutch/flywheel
Master Cylinder/Slave Cylinder
Clutch Lines
Shifter Plate
Shift Cables
3G GS ECU or EVO ECU

Quote:

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Originally Posted by lonestar22

so this thread is also turning into my manual swap thread now. i went and put a deposit in on a Hyundai Sonata transmission due to the price difference and how close it is to my house. So far no one has tried it yet and there is only little proof that it will fit but we are soon to find out. I still need pretty much ALL the other parts of the transmission.

heres the list of parts i THINK i need. there might be more if so let me know.

Hyundai Sonata transmission
Clutch/flywheel
Master Cylinder/Slave Cylinder
Clutch Lines
Shifter Plate
Shift Cables
3G GS ECU or EVO ECU

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master $38
slave $28
clutch $101
cables $120

the first two u can get from rock auto
clutch from ebay and cables from the dealer

question: why did you specify the ecu to be from a GS ??

gs rs it doesnt matter. i ordered all the other parts minus the clutch already actualy

Shifter base w/ shifter cables -$165
Clutch & Brake Pedals - $104
Clutch Master Cylinder/clutch lines/resevoir - $90

all these prices include shipping, i plan to get a ZOOM 6 puck from work.

Quote:

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Originally Posted by lonestar22

gs rs it doesnt matter. i ordered all the other parts minus the clutch already actualy

Shifter base w/ shifter cables -$165
Clutch & Brake Pedals - $104
Clutch Master Cylinder/clutch lines/resevoir - $90

all these prices include shipping, i plan to get a ZOOM 6 puck from work.

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what about the slave cylinder ??

did you order the master for the eclipse or the sonata tranny ??

slave is already on the tranny i picked up. and i used all the parts from the 3g except the slave thats on the tranny. i might use the clutch as well. they are the same diminsions as the eclipse one.

Quote:

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Originally Posted by lonestar22

slave is already on the tranny i picked up. and i used all the parts from the 3g except the slave thats on the tranny. i might use the clutch as well. they are the same diminsions as the eclipse one.

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since you experimenting with it why dont you buy the sonata master cylinder and try to see if it works with our pedals cuz i like the idea of having the reservoir mounted on it rather than remotly mounted

this is what i ended up running
sonata slave
eclipse master with steel braided line connecting the two since the hardline on the eclipse wouldnt work.
shifter cables work even though the weird orientation of the linkage, i assume the inside is different but shifts the same was on the outside as long as u switch the cables around.
eclipse clutch & flywheel. i decided to go with an ACT hi-per model.

also more good news!!!
my BC cams arrived today after being on back order, i already recieved all the other parts i ordered. now i just need cam gears and valve springs/retainers as far as internals go

did you use a full SS line between both ?? how long of a line did you use ??? i wanna do that for my tranny

Nice Thread hope you get the engine done shortly without problems.

Quote:

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Originally Posted by spdracr

did you use a full SS line between both ?? how long of a line did you use ??? i wanna do that for my tranny

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i used one we had around the shop and i didnt really measure it because it was long enough. but im sure you could pick one up from the EVO/ECLIPSE. that will give you more than enough line to work with

Hey just wondering what you are using for the intake manifold

Quote:

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Originally Posted by troubled4g64t

Hey just wondering what you are using for the intake manifold

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The intake manifold is from the Sonata which is the cylinder head he has on the 4g64 motor.

Nice job so far buddy keep it coming

yeah we'll I was at my local yard today got some leathers while there to but I saw a dohc sonata head but I didn't recognize that intake now is that the oem throttle body or the v6.

BTW he no longer has his 8g it was wrecked and I believe he is selling those parts.

hey lonestar those hose barbs you were asking about there are 2 of each one pair that you circled and the other pair is on the therm houseing where the water neck hooks up the larger of the to fittings goes to the heater core the smaller of the 2 both go to the throttle body prob. a fast idle valve but if ours doesn't have that option then just connect them both toghter as a bypass.